Control system for a top drive
First Claim
1. An automatically executing control system for a top drive for a drilling rig wherein the control system communicates with a hydraulic pump and a prime mover, wherein the control system comprises:
- (i) at least one processor;
(ii) data storage connected to the at least one processor;
(iii) a torque pin sensor connected to the at least one processor and mounted between the top drive and a torque track slide assembly for moving the top drive; and
(iv) a speed sensor connected to at least one of the processors and mounted integrally within the top drive;
b. a remote control connected to the processor, enabling a user to remotely perform at least one of four modes of operations at least partially automatically using the drill string by the top drive comprising a drill mode, a make-up mode, an orient mode, and a rocking mode, and wherein the remote control comprises;
(i) a torque control and monitor comprising;
1. a right hand torque and left hand torque display connected to the torque pin sensor for displaying simultaneously and in real time right hand torque pressure and left hand torque pressure applied to the drill string by a member of the group, comprising;
a. lithe top drive;
b. a mud motor; and
c. combinations thereof;
2. a torque release actuator;
3. a drill torque control connected to the hydraulic pump;
4. a make-up torque control connected to the processor; and
5. a mode of operation selection means;
(ii) a speed control and monitor comprising;
1. a speed display in revolutions per minute connected to the speed sensor for displaying revolutions per minute applied to the drill string in real time by the top drive;
2. a speed selection means connected to at least one of the processors; and
3. a rotational selection means to control rotation of the drill string wherein the rotational selection means allows a rotational direction to be selected, wherein the rotational direction comprises a clockwise rotation, a counter-clockwise rotation, and a stop;
c. computer instructions in the data storage to compare data from the torque pin sensor to a top drive torque maximum or a specified number of turns for the drill string to rock the drill string;
d. computer instructions in the data storage for establishing a maximum torque while drilling in a clockwise direction or a specified number of turns for the drill string in a clockwise direction; and
e. computer instructions in the data storage for establishing a maximum torque while rotating the drill string in a counter-clockwise direction or a specified number of turns for the drill string in a counter-clockwise direction.
1 Assignment
0 Petitions
Accused Products
Abstract
A top drive control system with a remote control having a processor and data storage connected to a torque pin sensor, a speed sensor, a remote control, which enables a user to actuate automatic remote rocking, drilling, orienting and making-up of a drill string using the top drive and provides simultaneous right hand and left hand torque applied to the drill string while simultaneously controlling speed of turning of the drill string. The top drive control system includes computer instructions for automated orienting of drill pipe, automated drilling with drill pipe and automated making-up of drill pipe into a drill string.
44 Citations
19 Claims
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1. An automatically executing control system for a top drive for a drilling rig wherein the control system communicates with a hydraulic pump and a prime mover, wherein the control system comprises:
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(i) at least one processor; (ii) data storage connected to the at least one processor; (iii) a torque pin sensor connected to the at least one processor and mounted between the top drive and a torque track slide assembly for moving the top drive; and (iv) a speed sensor connected to at least one of the processors and mounted integrally within the top drive; b. a remote control connected to the processor, enabling a user to remotely perform at least one of four modes of operations at least partially automatically using the drill string by the top drive comprising a drill mode, a make-up mode, an orient mode, and a rocking mode, and wherein the remote control comprises; (i) a torque control and monitor comprising; 1. a right hand torque and left hand torque display connected to the torque pin sensor for displaying simultaneously and in real time right hand torque pressure and left hand torque pressure applied to the drill string by a member of the group, comprising; a. lithe top drive; b. a mud motor; and c. combinations thereof; 2. a torque release actuator; 3. a drill torque control connected to the hydraulic pump; 4. a make-up torque control connected to the processor; and 5. a mode of operation selection means; (ii) a speed control and monitor comprising; 1. a speed display in revolutions per minute connected to the speed sensor for displaying revolutions per minute applied to the drill string in real time by the top drive; 2. a speed selection means connected to at least one of the processors; and 3. a rotational selection means to control rotation of the drill string wherein the rotational selection means allows a rotational direction to be selected, wherein the rotational direction comprises a clockwise rotation, a counter-clockwise rotation, and a stop; c. computer instructions in the data storage to compare data from the torque pin sensor to a top drive torque maximum or a specified number of turns for the drill string to rock the drill string; d. computer instructions in the data storage for establishing a maximum torque while drilling in a clockwise direction or a specified number of turns for the drill string in a clockwise direction; and e. computer instructions in the data storage for establishing a maximum torque while rotating the drill string in a counter-clockwise direction or a specified number of turns for the drill string in a counter-clockwise direction. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. An accelerated method for rocking a drill string using a top drive control system with a remote control, wherein the method comprises:
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a. using computer instructions in data storage of the control system of the top drive to instruct a processor connected to the data storage to initiate rock mode; b. using computer instructions to automatically increase a speed of the prime mover to a preset prime mover limit; c. using a make-up torque control and a torque control, both a right hand rock torque applied to the drill string is reduced to zero and a left hand rock torque applied to the drill string is reduced to zero; d. using computer instructions to limit the right hand torque and the left hand torque to a preset torque percentage that is less than 100 inside blow out preventer torque on the drill string; e. using a rotational selection means to control a rotation of the drill string to change rotation of the top drive from stop to a first directional rotation; f. using a first torque control to increase torque pressure in the first rotational direction and increase hydraulic fluid flow from hydraulic pump to a hydraulic motor of the top drive to establish a maximum torque pressure or a specified number of turns for the top drive in the first rotational direction; g. using the rotational selection means for selecting rotation of the drill string to stop pipe drill pipe rotation; h. using the rotational selection means for selecting rotation of the drill string to start rotation of the drill pipe in a second rotational direction; i. using a second torque control to increase torque pressure in the second rotational direction and increase hydraulic fluid flow from hydraulic pump to a hydraulic motor of the top drive to establish a maximum torque pressure or a specified number of turns for the top drive in the second rotational direction; j. using the rotational selection means to control rotation of the drill string to stop pipe drill pipe rotations; k. adjusting the speed of the drill string using a speed selection means simultaneously while rotating the drill pipe in the first or second rotational direction;
adjusting right hand torque on the drill string while rotating the drill string in the first or second rotational direction, adjusting left hand torque on the drill string while rotating the drill string in the first or second rotational direction, or combinations thereof;l. using computer instructions that increase hydraulic fluid flow from the hydraulic pump to the established maximum torque pressure or specified number of turns for the top drive in the first rotational direction; m. using computer instructions to verify that the drill pipe has stopped rotating in the first rotational direction and then change rotation from stop to a second directional rotation; n. using computer instructions that increase hydraulic fluid flow from the hydraulic pump to the established maximum torque pressure or specified number of turns for the top drive in the second rotational direction; o. using computer instructions to verify that the drill pipe has stopped rotating in the second rotational direction and then change rotation from stop to the first directional rotation; p. using computer instructions to repeat the changing of rotational directions for as long as indicated by a user; and q. using computer instructions to display drill string speed and right hand torque and left hand torque on the drill string continuously to a user while operating the top drive in rocking mode. - View Dependent Claims (15)
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16. An at least partially automated method for rotating a drill string for making-up drill pipe using a top drive control system with a remote control, wherein the method comprises:
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a. using computer instructions in data storage of the control system of the top drive to instruct the processor to initiate make-up mode; b. using computer instructions in data storage of the control system of the top drive to instruct the processor to grab drill pipe with the grabber; c. using a rotational selection means for selecting rotation of the drill string to select a rotation of the top drive; d. using computer instructions in data storage of the control system of the top drive to instruct the processor to set a speed of rotation of the drill pipe to a maximum speed; e. increasing the speed of rotation by at least 10 percent using a speed selection means until the pipe breaks out or makes up; and f. releasing the drill pipe with the grabber.
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17. An at least partially automated method for orienting a drill string in a wellbore using a top drive control system with a remote control, wherein the method comprises:
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a. using computer instructions in data storage of the control system of the top drive to instruct the processor to initiate orient mode; b. using computer instructions in the data storage of the control system to limit rotation of the drill string to no more than 10 percent of maximum revolutions per minute of the top drive; c. using a rotational selection means to control rotation of the drill string to a first rotational direction or a second rotational direction; d. using computer instructions in data storage of the control system of the top drive to instruct the processor to increase a speed of rotation of the drill pipe to a orient the drill string to a user selected position; e. setting the brake of the top drive using a brake set and release; and f. using the rotational selection means to control rotation of the drill string to stop drill string rotations.
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18. An automated method for setting torque for drilling mode of a top drive using a top drive control system with a remote control, wherein the method comprises:
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a. using computer instructions in data storage of the control system of the top drive to instruct the processor to stop rotation of the drill string; b. using computer instructions in data storage of the control system of the top drive to instruct the processor to release the brake of the top drive; c. using computer instructions in data storage of the control system of the top drive to instruct the processor to set speed of rotation to a minimum speed; d. using computer instructions in data storage of the control system of the top drive to instruct the processor to set the grabber to grab the drill string; e. using computer instructions in data storage of the control system of the top drive to instruct the processor to set the mode of operation to drill mode; f. using computer instructions in data storage of the control system of the top drive to instruct the processor to set drill torque pressure to a minimum setting; g. using computer instructions in data storage of the control system of the top drive to instruct the processor to change a preset maximum torque value for drilling in the data storage to zero; h. using computer instructions in data storage of the control system of the top drive to instruct the processor to start turning the drill string in a clockwise rotational direction; i. using computer instructions in data storage of the control system of the top drive to instruct the processor to increase speed of rotation of the drill string by at least 10 inside blow out preventer; j. using computer instructions in data storage of the control system of the top drive to instruct the processor to increase torque pressure while drilling to a desired maximum pressure; k. using computer instructions in data storage of the control system of the top drive to instruct the processor to decrease speed of rotation of the drill string in rpm to zero; l. using computer instructions in data storage of the control system of the top drive to instruct a processor to stop drill string rotation; m. using computer instructions in data storage of the control system of the top drive to instruct the processor to set a grabber position to open; n. using computer instructions in data storage of the control system of the top drive to instruct the processor to limit torque pressure while drilling to a desired maximum pressure; and o. using computer instructions in data storage of the control system of the top drive to instruct the processor to display drill string speed and right and torque and left hand torque on the drill string continuously to a user while operating the top drive in drilling mode.
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19. An automated method for setting torque for make-up mode of a top drive for a drill string using a top drive control system with a remote control, wherein the method comprises:
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a. using computer instructions to set torque for make-up mode; b. using computer instructions to instruct the processor to stop rotation of the drill string; c. using computer instructions to instruct the processor to release the brake of the top drive; d. using computer instructions to instruct the processor to set speed of rotation of the top drive to a minimum speed of rotation; e. using computer instructions to instruct the processor to grab drill pipe with the grabber; f. using computer instructions to instruct the processor to operate the top drive in make-up mode; g. using computer instructions to instruct the processor to set make-up torque pressure to minimum, and then using computer instructions to instruct the processor to change a preset maximum torque value in the data storage to zero; h. using computer instructions to instruct the processor (i) to rotate the drill string in a clockwise rotational direction;
(ii) to increase the speed of rotation by at least 10 percent;
(iii) to increase torque pressure to a desired maximum;
(iv) to decrease drill pipe rotation speed to zero;
(v) to verify rotation of the drill pipe has stopped and to open the grabber; andi. using computer instructions to instruct the processor to display drill string speed and torque continuously to a user while orienting the top drive.
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Specification